Cement-Lock SM Technology for Decontaminating Dredged Sediment Amir Rehmat, Anthony Lee Gas Technology Institute Michael Mensinger, Anil Goyal ENDESCO Services, Inc. Fall 2000 ITRC Conference October 18, 2000
Cement-Lock SM Technology An advanced thermo-chemical manufacturing process for decontaminating dredged sediments, soils, wastes, and sludges and transforming these wastes into resources: Sediment is transformed into constructiongrade cement Organic contaminants are destroyed with DRE s > 99% Heavy metals are immobilized in the cement matrix
Cement-Lock SM Technology Description STEAM SEDIMENT FUEL AIR/O 2 MODIFIERS ECOMELT GENERATOR 2400-2600 F SECONDARY COMBUSTION ADDITIVE HEAT RECOVERY GAS CLEAN UP CLEAN FLUE GAS ECOMELT QUENCH PULVERIZER/ MIXER High Quality CONSTRUCTION- GRADE CEMENT
Cement-Lock SM Technology Supporters U.S. EPA Region 2 Brookhaven National Laboratory U.S. Army Corps of Engineers U.S. EPA Region 5 / GLNPO MI Dept. of Env. Quality NJ Office of Maritime Resources NJ Dept. of Transportation GRI Unitel Technologies, Inc. Private Corporations
Cement-Lock SM Technology Applications Harbor & river sediments MGP site soils Brownfield soils, debris Superfund site soils Military BRAC wastes, debris Municipal solid wastes & sludges Petroleum sludges Tank / tanker bottoms Spent molecular sieves, etc. Coal ash, etc.
Cement-Lock SM Technology -- Wastes Tested Dredged estuarine sediments Dredged river sediments Municipal solid waste MSW incinerator ash Contaminated concrete Coal fly ash Coal bottom ash Oil-contaminated soil PCB-contaminated soils U-containing wastes
Technology Development Status for Dredged Sediment Bench-scale data with Newtown Creek (NY) sediment - WRDA (COE/EPA2/BNL) and Black Lagoon (Detroit River) sediment - MI-DEQ Pilot-scale (1-ton/day) data with Newtown Creek sediment and contaminated soil - WRDA (COE/EPA2/BNL), private sector Demo plant (30,000-150,000 cy) for dredged sediment currently under construction for NJ - WRDA (COE/EPA2/BNL), NJ-MR, private sector
Technology Development Status for Dredged Sediment Demo plant (2,000-5,000 cy) for Black Lagoon (Detroit River) sediment - EPA5, GLNPO, MI-DEQ, private sector Engineering completed for 100,000 cy/yr plant module and 500,000 cy/yr plant Cost for complete dredged sediment-tocement production plant (1 module of 100,000 cy/yr capacity) is $20 million.
Independent Data Verification Organic Contaminant Destruction Triangle Laboratories, Durham, NC Metals Immobilization Triangle Laboratories, Durham, NC Air Sampling Data AirNova, Pennsauken, NJ
Cement-Lock SM is Very Effective in Destroying Organic Contaminants Contaminant ------ Estuarine Sediment ------ ---------- River Sediment ---------- Untreated Cement Untreated Cement Sediment Product Destruction Sediment Product Destruction ----- mg/kg (dry) ----- --%-- ----- mg/kg (dry) ----- --%-- Oil & Grease - - - - - - 18,000 < D.L.* > 99.99 PAHs 370 0.22 99.93 51.2 < D.L. 99.99 ------ m g/kg (dry) ----- ------ m g/kg (dry) ------ PCBs 8,585 < D.L. > 99.99 1,100 < D.L. > 99.99 ----- ng/kg(dry) ----- Dioxins/Furans 2,3,7,8 TCDD/F 262 < D.L. > 99.99 Other TCDD/F 2,871 < D.L. > 99.99 PeCDD/F 4,363 < D.L. > 99.99 Hx/Hp/OCDD/F 34,252 < D.L. > 99.99 * Below the analytical method detection limit.
Cement-Lock SM is Very Effective in Immobilizing Inorganic Contaminants Metal Untreated Material Estuarine Sediment River Sediment Toxicity Characteristic Leaching Procedure Cement Produced From Estuarine River Regulatory Sediment Sediment Limit ------ mg/kg (dry) ------ -------------------- mg/l -------------------- Arsenic 39 7.8 < 0.005* < 0.01 5 Cadmium 27 9.5 < 0.001 < 0.002 1 Chromium 298 138 0.15 < 0.072 5 Copper -- 180 -- < 0.01 -- Lead 542 218 < 0.002 < 0.01 5 Mercury 2.9 0.55 < 0.0004 < 0.0004 0.2 Selenium 6.2 -- < 0.003 -- 1 Silver 13 -- < 0.001 -- 5 * Analytical method detection limit.
Cement-Lock SM Pilot-Scale Unit
Ecomelt produced during pilot-scale testing
Cement-Lock SM Technology Pilot-Scale Air Emissions Flue Gas Composition* Outlet CO2, mol % 8.1 CO, ppm 25 HCl, ppm 14.2 NOx, ppm 67.7 SO 2, ppm 44.1 Total Hydrocarbons, ppm 10.6 PCBs < 1.1 x10-6 lb/hr Pesticides < 2.8 x 10-7 Chlorobenzenes/Chlorophenols < 6.8 x 10-5 SVOCs BDL** Total 2,3,7,8-CDDs (TEF) < 4.0 x 10-12 Total 2,3,7,8-CDFs (TEF) < 8.1 x 10-12 Particulates, grains/dscf < 2.0 x 10-4 Particulate Phase Composition PCBs < 5.3 x 10-7 Total 2,3,7,8-CDDs (TEF) < 8.0x10-12 Total 2,3,7,8-CDFs (TEF) < 7.3x10-13 * Adjusted to 7% oxygen ** Below detection limit, some phthalate compounds detected
Cement Certification & Testing Construction Technology Laboratories, Inc. (CTL, Skokie, IL, subsidiary of Portland Cement Association) Prairie Cement Group (Chicago, IL, cement manufacturer) New Jersey Department of Transportation (NJ-DOT, public project applications) Sor Testing Laboratories (Cedar Grove, NJ, cement/concrete testing services for NJ/NY area)
Compressive Strength of Cement from Sediment and Debris Compressive Strength, psi 6000 5000 4000 3000 2000 1000 3 Days 7 Days 28 Days 28-day portland cement requirement: 4060 psi 0 Estuarine Sediment River Sediment Concrete Debris Feedstock
Compressive Strength of Cement from Ash Compressive Strength, psi 6000 5000 4000 3000 2000 1000 0 3 Days 7 Days 28 Days 28-day portland cement requirement: 4060 psi CF1* CF2* CF3* CB1* CB2* CB3* MSW1** Formulations *Cement made from grinding various formulations of Ecomelt with 75 wt% additives. **Cement made from grinding Ecomelt with 60 wt% additives.
Compressive Strength of Cement from Contaminated Soils Compressive Strenght, psi 6000 5000 4000 3000 2000 1000 28-day portland cement requirement: 4060 psi 3 Day 7 Day 28 Day 0 Petroleum Contaminated Soils Soils Contaminated with 9,100 ppm of PCB Equivalent MSW Feedstock
Comparison of Trace Elements in Cement- Lock SM Cement & Portland Cement Element Cement-Lock Cement Portland Cement* ---------- Range ---------- -------------------------- mg/kg -------------------------- Mercury < 0.07** < 0.001 0.039 Selenium < 0.94 0.62 2.23 Cadmium 1.59 0.03 1.12 Lead 35.8 1 75 Silver 2.66 6.75 19.9 Arsenic 9.22 5 71 Barium -- 91 1402 Chromium 196 25 422 Nickel 133 15 129 * Portland Cement Association, 1992 ** Below analytical detection limit
Factors Affecting Technology Performance Factor Moisture content Variations in type & quantity of organic contaminants Variations in type & quantity of heavy metals Sediment quality (clayey, loamy, sandy) Sediment particle size Effect No effect No effect No effect No effect No effect
Factors Affecting Technology Economics Factor Moisture content Non-steady supply Use of alternate fuels (sewage sludge and/or refinery tank bottoms) Non-continuous batch processing of sediment aliquot Effect Affects quantity of cement / revenues Larger storage required - affects capital costs Considerably reduces sediment treatment costs Capital attributed to batch increases processing cost
Logistical & Regulatory Requirements Permit requirements - similar to those for manufacturing process plants Air permit required Net water user - No process water discharge permit needed Large-scale plant (>500,000 cy/yr) incorporates engineered transportation and logistics system so that dredged sediment is moved from the channel to the cement market seamlessly
Logistical & Regulatory Requirements Small-scale plant (<100,000 cy/yr) is compartmentalized - specifically for final cement production, which is accomplished at off-site location Flexible with respect to siting in terms of site preparation and utility requirements
Net Cost of Sediment Treatment - 3 Scenarios 1. Dedicated 500,000 cy/yr sediment treatment facility; 20-year life span; fueled by natural gas; cement commanding the same price as portland cement. 2. Dedicated 500,000 cy/yr sediment treatment facility; 20-year life span; fueled by sewage sludge and/or refinery tank bottoms; cement commanding the same price as portland cement. 3. Case 2 except with cement commanding 50% of the price of portland cement.
Unit Processing Costs for a 500,000 yd 3 /year Capacity Plant Case 1 Case 2 Case 3 Credits ---------------------- $1000 s ---------------------- Sale of Cement ($70/ton) $17,440 $23,100 $11,550 Tipping Fees From Other Wastes -- 18,810 18,810 Total Credits $17,440 $41,910 $30,360 Expenses Labor $930 $930 $930 Raw Materials 3,470 4,035 4,035 Utilities 12,110 6,055 6,055 Maint./Misc. 5,775 5,775 5,775 Total Expenses $22,285 $16,795 $16,795 Provision for Lease $1,500 $1,500 $1,500 Depreciation $10,500 $10,500 $10,500 Net Processing Cost $16,845 ($13,115) $1,565 Break-Even Tipping Fee, $/yd 3 $33.69 ($26.23) $3.13 Case 1: 100% harbor sediment feed Case 2: 75% harbor sediment feed + 25% other waste feed Case 3: Case 2 except cement sale price reduced by 50%
Commercial Readiness All equipment is commercially available Vendors are willing to provide turnkey plants: ABB, Svedala, Andersen 2000 Pilot plant data sufficient for detailed design and construction
Commercial Readiness Modular plant construction 100,000 cy/y modules Modules can be added as needed Additional environmental and cement utilization data will be generated at the NJ demo facility
Cement-Lock SM Technology -- Summary Simple, one-step method for processing large volumes of sediment, soil, MSW, etc. with practically no restrictions on their content. All processing equipment is commercially available. No development required Provides a permanent solution for disposing of dredged sediment Favorable economics Tipping/processing fees Finished product sales (ASTM quality construction-grade cement) Industrial wastes co-processing